Rotating Build Platform for Simultaneous Additive-Subtractive Manufacturing
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Solution Overview
Problem
Current additive manufacturing technologies, such as powder bed fusion, are limited in size due to the constraints of the powder bed, leading to challenges in producing large objects with improved precision and efficiency while minimizing material waste.
Innovation Solution
A large-scale manufacturing apparatus featuring a rotating build platform with integrated powder delivery and machining mechanisms, allowing for real-time simultaneous additive and subtractive manufacturing processes, including powder recoating, irradiation, and automated material removal, which can handle large objects like aircraft engine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the powder bed size is increased to manufacture larger objects, then the manufacturing scale is improved, but the scan quality deteriorates due to large angle of incidence and the system weight exceeds stepper capabilities
Solution Approach 1:
The patent transitions from a static powder bed system to a dynamic rotating build platform system. The build platform rotates during the additive manufacturing process, allowing the laser to maintain a consistent angle of incidence while building large-diameter annular objects. This dynamic approach enables large-scale manufacturing without sacrificing scan quality, as the rotation compensates for the large radius and maintains optimal laser-powder interaction geometry throughout the build process
Solution Approach 2:
The patent introduces rotational motion as a new dimension to the traditional linear XY powder bed system. By adding the rotational degree of freedom, the system can manufacture large-diameter annular objects that would be impossible in a static rectangular build volume. The rotation enables the laser to access all regions of the annular object while maintaining a consistent working angle, effectively expanding the manufacturable size without compromising precision
2Volume of moving object
If the powder bed size is increased to manufacture larger objects, then the manufacturing scale is improved, but the system weight increases beyond stepper capabilities
Solution Approach 1:
The patent replaces the heavy static powder bed with a lighter rotating build platform. Instead of moving the entire large powder bed with steppers, the system uses a motor-driven rotation of the build platform itself. This dynamic approach significantly reduces the weight that needs to be supported by precision positioning systems, as only the platform and its immediate contents need to be moved, not the entire powder reservoir structure
Solution Approach 2:
The patent substitutes the traditional stepper-motor-based XY positioning system with a rotational motor system. This mechanical substitution allows for large-scale manufacturing without the weight constraints of stepper capabilities, as rotational systems can handle larger masses more efficiently than linear stepper systems. The rotation mechanism provides the necessary positioning accuracy through angular control rather than linear displacement
3Loss of substance
If additive manufacturing is used to produce large components, then material waste is reduced, but production time increases due to layer-wise building process
Solution Approach 1:
The patent merges additive and subtractive manufacturing processes into a single integrated system. The annular object is built additively layer-by-layer while a machining tool simultaneously performs subtractive operations to machine the outer surface. This combination allows the bulk of the material to be deposited efficiently through additive processes (minimizing waste), while the time-consuming precision machining is performed concurrently on the rotating object, thereby reducing total production time
Solution Approach 2:
The patent enables continuous simultaneous operation of both additive and subtractive processes. While the build platform rotates and deposits powder layers, the machining tool continuously machines the outer surface without interruption. This continuous parallel operation eliminates the sequential nature of traditional manufacturing, where additive building must be completed before machining begins, thereby significantly reducing overall production time while maintaining material efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient production of large, complex components with enhanced precision and reduced material waste by integrating additive and subtractive processes, facilitating the creation of large-scale objects like annular aircraft components with improved time and cost efficiency.
Implementation Method 1
a focused energy beam is used to fuse powder particles together on a layer-wise basis. The energy beam may be either an electron beam or laser.
Implementation Method 2
a focused energy beam is used to fuse powder particles together on a layer-wise basis. The energy beam may be either an electron beam or laser.
Implementation Method 3
The machining mechanism is configured to carry one or more material removal processes, e.g. cutting, tapping, tooling, drilling, chamfering, abrading, forming, grinding, shaping and knurling
Data Source
AI summary
A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.